Ratchet mechanism spring

ABSTRACT

A spring component for a ratcheting mechanism, such as a ratchet wrench. The spring component is shaped to be retained in a recess without any special machining. For example, the spring component can be retained at three abutment points. A leaf of the spring component can abut a pawl, and a base portion opposite the leaf can abut the drive gear. Support arms can abut the sidewall of the recess to retain the spring component within the recess without the need for special machining or tooling.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to provisional application No.62/080,547, filed Nov. 17, 2014, the contents of which are incorporatedby reference herein in their entirety.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to ratchet mechanisms and, inparticular, to springs for retaining pawls of the ratchet mechanisms.

BACKGROUND OF THE INVENTION

Currently, many ratchet mechanisms are known and used. Typically, thesemechanisms are incorporated into hand tools, such as wrenches orscrewdrivers. Such tools allow for a drive portion to be engageablewith, for example, a bolt head. In general, the ratchet mechanismincludes a drive direction for use in applying torque to a fastener.Additionally, the ratchet mechanism typically allows for slipping orratcheting when rotated in a direction opposite the drive direction.

In conventional ratchet mechanisms, such as in ratchet wrenches, aspring mechanism typically biases a pawl into engagement with a drivegear to allow the ratchet mechanism to apply torque in the driveportion, while also allowing for slipping or ratcheting when rotated inthe opposite direction. However, such spring mechanisms tend to becomposed of multiple parts and may require machining to enable thecorrect placement and operation of the ratchet wrench. For example, manyconventional ratchet mechanisms include a hoop spring that extendsaround a periphery of the drive gear and couples with the pawl in a pawlpocket. The hoop spring requires a circumferential groove to be formedin the interior of the wrench head, increasing costs and the complexityof the wrench.

SUMMARY OF THE INVENTION

The present invention broadly comprises a spring component for biasing apawl against a drive gear in a ratchet mechanism. For example, thespring component is shaped to be retained in a recess within a head of aratcheting mechanism tool, such as a ratchet wrench, and biases the pawltowards the drive gear, without any special machining or additionalcomponents. The spring component can include a leaf that applies a biasforce against the pawl, and a base portion opposite the leaf that abutsor contacts the drive gear. Another portion of the spring component canabut the sidewall of the recess to retain the spring component withinthe recess without the need for special machining or tooling.

In an embodiment, the present invention broadly comprises a springcomponent including a base portion, a leaf opposite the base portion andadapted to contact a pawl, and a support arm extending from the baseportion and adapted to abut a wall of a recess to retain the springportion within the recess.

In another embodiment, the present invention broadly comprises a toolincluding a drive gear, a pawl adapted to be coupled to the drive gearand engage the drive gear to allow rotation of the drive gear in a drivedirection, and disengage and slip against the drive gear in a ratchetingdirection opposite the drive direction, a head having a recess formedtherein, the recess including a wall, and a spring component. The sprintcomponent can include a base portion, a leaf opposite the base portionand adapted to abut the pawl, and a support arm extending from the baseportion and adapted to abut the wall.

In another embodiment, the present invention broadly comprises a springcomponent for a ratchet mechanism including a base portion, a leafextending from the base portion in a first direction and in a same planeas the base portion, the leaf adapted to bias a pawl of the ratchetmechanism into engagement with a drive gear of the ratchet mechanism, afirst support arm extending from a first side of the base portion and ina second direction substantially perpendicular to the plane of the baseportion, and a second support arm extending from a second side of thebase portion opposite the first side, and in the second direction. Thefirst and second support arms are adapted to position the springcomponent in a recess of the ratchet wrench to allow the ratchet wrenchto apply torque when rotated in a drive direction and slip against thedrive gear when rotated in a ratcheting direction opposite the drivedirection.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of facilitating an understanding of the subject mattersought to be protected, there are illustrated in the accompanyingdrawings embodiments thereof, including a preferred embodiment, from aninspection of which, when considered in connection with the followingdescription, the subject matter sought to be protected, its constructionand operation, and many of its advantages should be readily understoodand appreciated.

FIG. 1 is a top perspective view of a spring component of a ratchetmechanism according to an embodiment of the present invention.

FIG. 2 is a top plan view of the spring component of FIG. 1.

FIG. 3 is a rear elevation view of the spring component of FIG. 1.

FIG. 4 is a side elevation view of the spring component of FIG. 1.

FIG. 5 is an exploded perspective view of a ratchet mechanism accordingto an embodiment of the present invention.

FIG. 6 is a top plan view of the ratchet mechanism of FIG. 5, partiallyassembled.

DETAILED DESCRIPTION OF THE EMBODIMENTS

While this invention is susceptible of embodiments in many differentforms, there is shown in the drawings, and will herein be described indetail, embodiments of the invention, including a preferred embodiment,with the understanding that the present disclosure is to be consideredas an exemplification of the principles of the invention and is notintended to limit the broad aspect of the invention to embodimentsillustrated. As used herein, the term “present invention” is notintended to limit the scope of the claimed invention and is instead aterm used to discuss exemplary embodiments of the invention forexplanatory purposes only.

The present invention broadly comprises a spring component for aratcheting mechanism, such as found in a ratchet wrench. For example,the spring component is shaped to be independently retained in a recesswithout any special machining. The spring component can include a leafat a first side and a base portion at a second side opposite the firstside. The leaf applies a bias force against the pawl, and the baseportion abuts the drive gear in a passive manner to retain the springcomponent against the drive gear without substantially affecting therotation of the drive gear. Another portion of the spring component canabut a sidewall of the recess to retain the spring component within therecess without the need for special machining or tooling.

In an embodiment, a spring component 100 for a ratcheting mechanism,such as, for example, located in a ratchet wrench, is described withreference to FIGS. 1-4. The spring component 100 is elastic and includesa base portion 102, a leaf 104, a first support arm 106, and a secondsupport arm 108. In an undistorted position (e.g., no force applied tocause elastic deformation), the leaf 104 extends from the base portion102 in a first direction in a same plane as the base portion 102. In adistorted configuration (e.g., a force is applied to cause elasticdeformation), as shown in FIG. 6, the leaf 104 and base portion 102 canbe disposed at an angle relative to each other. The angle can be larger(i.e., more flat) when the pawl is engaged with the drive gear, andsmaller (i.e., more angled) when the pawl disengages and slips againstthe drive gear. The leaf 104 can also include a leaf width W1 that isless than a base width W2 of the base portion 102, as illustrated inFIG. 2.

The first support arm 106 extends from a first side of the base portion102, and extends in a second direction substantially perpendicular tothe plane of the base portion 102. Similarly, the second support arm 108extends from a second side of the base portion 102, opposite the firstside, and extends in the second direction substantially perpendicular tothe plane of the base portion 102. The first and second support arms106, 108 also extend in a direction parallel to the first directionforming respective spaces or gaps 110, 112 respectively between thefirst and second support arms 106 and 108 and the bias prong 104. Thesegaps 110, 112 allow the leaf 104 to flex and apply the requisite amountof bias against a pawl, without the leaf 104 contacting the support arms106, 108 when flexed.

The first and second support arms 106, 108 respectively include arcuateedges 114, 116 distal to the leaf 104 to allow the spring component 100to abut a sidewall of a recess in the tool, as described in furtherdetail below. As shown, the edges 114, 116 can be arcuate to allow asmooth rocking movement of the spring component 100 during use.

Referring to FIGS. 5 and 6, the spring component 100 can be shaped tofit within a recess 118 in a head 120 of a tool 122, such as, forexample, a ratchet wrench. For example, the ratchet wrench 122 mayinclude the head 120, the recess 118 in the head 120, and an opening 124in the head 120 in communication with the recess 118. A drive gear 126can be disposed in the opening 124, and a pawl 128 can be disposed inthe recess 118. The pawl 128 can be movably engagable with the drivegear 126 to engage the drive gear 126 in the drive direction, but slipsagainst or otherwise disengages the drive gear 126 in a ratchetingdirection opposite the drive direction.

The spring component 100 can be disposed in the recess 118 between thedrive gear 126 and a sidewall of the recess 118. For example, the springcomponent 100 can abut the drive gear 126 at the base portion, abut thepawl 128 at the leaf 104, and abut the sidewall of the recess 118 at theedges 114, 116 opposite the leaf 104. The bias force from the leaf 104can cause pawl teeth 130 of the pawl 128 to engage gear teeth 132 of thedrive gear 126. This engagement enables the ratchet wrench 122 to applytorque when rotated in a drive direction.

The spring component 100 also allows for slipping or ratcheting whenrotated in a ratcheting direction opposite the drive direction. Forexample, when the ratchet wrench 122 is rotated in the ratchetdirection, the leaf 104 allows the pawl 128 to shift against the biasforce and out of engagement with the ratchet gear 126. In this manner,the leaf 104 may elastically flex or bend to allow the pawl 128 to shiftout of engagement with the ratchet gear 126 and allow for slipping orratcheting when the ratchet wrench 122 rotated in the ratchetingdirection. When rotated back in the drive direction, however, the leaf104 returns to its normal state and applies a bias force to the pawl 128to re-engage the drive gear 126 and allow the ratchet wrench 122 toapply torque to a work piece.

The shape of the spring component 100 independently retains the springcomponent 100 in the recess 118. The spring component 100 does notrequire any special machining or additional component to position andretain the spring component 100 in the recess 118. Rather, the springcomponent 100 can be independently retained within the recess 118 byfrictionally abutting the pawl 128 with the leaf 104, by frictionallyabutting the drive gear 126 with the base portion 102, and byfrictionally abutting a sidewall of the recess 118 with the support arms106, 108, for example, at the edges 114, 116.

It will also be appreciated that the tool 122 may include a drive lugextending from the drive gear 126 for mating with a socket type adaptor,or a recess disposed in the drive gear 126. The socket type adaptorand/or recess may be adapted to engage a work piece for providing torqueto the working piece, such as a head of a fastener or other tool.

As used herein, the term “coupled” and its functional equivalents arenot intended to necessarily be limited to direct, mechanical coupling oftwo or more components. Instead, the term “coupled” and its functionalequivalents are intended to mean any direct or indirect mechanical,electrical, or chemical connection between two or more objects,features, work pieces, and/or environmental matter. “Coupled” is alsointended to mean, in some examples, one object being integral withanother object.

The manner set forth in the foregoing description and accompanyingdrawings and examples, is offered by way of illustration only and not asa limitation. More particular embodiments have been shown and described,and it should be apparent to those skilled in the art that changes andmodifications may be made without departing from the broader aspects ofthe disclosure. The actual scope of the protection sought is intended tobe defined in the following claims when viewed in their properprospective based on the prior art.

What is claimed is:
 1. A ratchet mechanism comprising: a drive gear; apawl adapted to engage the drive gear when the drive gear is rotated ina drive direction, and slip against the drive gear when the drive gearis rotated in a ratcheting direction opposite the drive direction; arecess with a wall; and a spring component disposed in the recess andincluding: a base portion extending in a first plane; a leaf extendingfrom the base portion and adapted to abut and bias the pawl intoengagement with the drive gear; and a support arm extending from thebase portion to an arcuate edge, and having a length and width thatextend in a second plane substantially perpendicular to the first plane,wherein the arcuate edge abuts the wall with a rocking movement duringuse of the spring component.
 2. The ratchet mechanism of claim 1,wherein the leaf extends at an angle relative to the base portion. 3.The ratchet mechanism of claim 2, wherein the angle is a first anglewhen the pawl engages the drive gear, and the angle is a second anglewhen the pawl slips against the drive gear to allow rotation of thedrive gear in the ratcheting direction, wherein the first angle isgreater than the second angle.
 4. The ratchet mechanism of claim 1,wherein the base portion has a base width and the leaf has a leaf width,wherein the base width is larger than the leaf width.
 5. The ratchetmechanism of claim 1, further comprising a gap disposed between the leafand the support arm.
 6. A ratcheting tool comprising: a drive gear; apawl adapted to engage the drive gear when the drive gear is rotated ina drive direction, and slip against the drive gear when the drive gearis rotated in a ratcheting direction opposite the drive direction; ahead having a recess with a wall; and a spring component disposed in therecess and including: a base portion extending in a first plane andhaving a base width; a leaf extending from and at an angle relative tothe base portion, and adapted to abut and bias the pawl into engagementwith the drive gear, wherein the angle is a first angle when the pawlengages the drive gear, and the angle is a second angle when the pawlslips against the drive gear to allow rotation of the drive gear in theratcheting direction, wherein the first angle is greater than the secondangle, and the leaf has a leaf width smaller than the base width; asupport arm extending from the base portion to an arcuate edge, andhaving a length and width that extend in a second plane substantiallyperpendicular to the first plane, wherein the arcuate edge abuts thewall with a rocking movement during use of the spring component; and agap disposed between the leaf and the support arm.